Turnkey steam network revamp for a five-star hotel in Indonesia, cutting gas consumption by 14%

A five-star hotel in Indonesia was running two 1TPH (2205 Pounds per hour) and one 2TPH (4409 Pounds per hour) coil type boilers to meet its steam requirements. Their existing boiler setup was inefficient, operating at 5-6barg with high fuel and water consumption. The feedwater temperature was between 40°C to 50°C (104°F to 122°F), due to venting of flash steam and 50-60% condensate recovery, resulting in substantial energy losses. We partnered with the hotel across the complete cycle of identifying savings, design engineering, supplying boilers and steam system accessories and implementation support for the project.

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PROBLEM

A five-star hotel in Indonesia needed to revamp their boiler house and steam and condensate network. They had poor steam quality due to the coil type boilers in use, necessitating the operation of multiple boilers to cater to the hotel load. Steam generation and distribution occurred at low pressure (5barg) with unnecessary multiple steam supply lines from the boiler house to the process, complete venting of flash steam and partial condensate recovery.

SOLUTION

Forbes Marshall conducted a detailed audit of the plant to identify gaps in the existing steam system. Based on a heat mass balance of the existing system, we recommended reducing boiler capacity to 2 shell type boilers of 1.5 TPH (3307lb/h) each and rationalisation of the distribution network from 4 lines to a single 100NB line.

In order to enhance steam distribution pressure, the existing system was replaced with our own pressure reducing station (FMPRS) and relocated from the boiler house to the process area.

A boiler efficiency monitoring system (EffiMax™) was installed to monitor real time boiler performance.

By automating blowdown control we were able to optimise boiler water total dissolved solids (TDS) reducing blowdown losses.

A FlashJet™ Pump was also installed to eliminate venting of flash steam and optimise condensate recovery.

These interventions collectively improved energy efficiency, and ensured reliable, sustainable boiler operation for the plant.

BENEFITS

Boiler installed capacity changed from 4TPH (1TPH x2 & 2TPH x1) coil type to 3TPH (1.5TPH x2) shell type boilers ; i.e. 8818 Pounds per hour (2205lb/h x2 & 4409lb/h x1) coil type to 6614lb/h (3307lb/h x2) shell type boilers

Steam generated and distributed at 8-9barg instead of 5-6barg

Blowdown operation automated with 3500pmm TDS (previously manual with 1500ppm TDS)

Real-time monitoring of boiler efficiency and losses available through EffiMax™

Feedwater tank capacity reduced from 10 to 4 Kilolitres (2642 to 1057 Gallons)

Feedwater temperature increased from 40-50°C (104-122°F) to 90°C (194°F)

Condensate recovery factor improved from 50-60% to 90-95%

No flash venting

Makeup water to boiler reduced from 20 to 5 Kiloliters per day (5283 to 1321 Gallons per day)

Fuel (gas) consumption reduced from 35,000 to 29,800 cubic meters per month (1.23 million to 1.05 million cubic feet per month)